Having trouble installing vac disconnect, please help

[BFJ93YJ]

I got a new vacuum motor yesterday, so I am trying to install the new shafts and motor today. I ran into a problem. When I connect the inner/outer shaft combo to the intermediate shaft and slide it all in, it sticks out about 1 1/2 inches (see pic)

http://img.photobucket.com/albums/v189/BFJ93YJ/Miscellaneous/P1010006.jpg

This pic is of just the intermediate shaft in the axle. Viewed through the vac disconnect space
http://img.photobucket.com/albums/v189/BFJ93YJ/Miscellaneous/P1010004.jpg

Pic with both intermediate and inner/outer combo shafts in place as far in as they will go
http://img.photobucket.com/albums/v189/BFJ93YJ/Miscellaneous/vac.jpg

It feels like everything is in as far as it will go, as nothing will budge. It feels like the intermediate shaft is in the carrier because it wont spin freely. Is it possible that the intermediate shaft isn't all the way into the carrier? Any other tips you can give me? TIA!

Btw, I am installing shafts from a 1995 YJ (297 u-joints). The driver's side went in without any problems, so I don't think that's it.

[zman]

I can't tell for certain if you really have a problem. Look at your drivers side and compare the two. The center of the u-joint should line up with your knuckles ball joints, if they are off it will bind when you try to turn. Your 95 axels should work fine so that is not your problem. It could also be possible that your intermeadiate shaft is not in all the way. Maybe when you removed stuff it slide over and now a foreign object is in the way.

zman

[Joe Dillard]

I agree with zman. :)

Looks to be very close to what mine looks like with the Warn inner & outer axles installed.


http://www.fototime.com/5DF4DF60B3836C8/standard.jpg

[Rock WoRM]

Dang, Joe, how do U keep everything so clean and pretty?:D

[Joe Dillard]

-=- originally posted by Rock WoRM -=-
Dang, Joe, how do U keep everything so clean and pretty?:D
Hehehe, I took that pic while I was installing it over at mrblaines house. :D Heck - we live in a desert out here anyway (up until our most recent rainfall :D).

[BFJ93YJ]

Zman and Joe: Thanks for the replies. The more I look at it, the more I think you guys are right. I compared it to the driver's side, and it looks to be in about the same place. I think it is in the correct place, it just looks different without all of the other stuff on there:). I'll fit it back in tomorrow and try to put it all back together and see if it fits. I'll let you know if it works.

Thanks again

[BFJ93YJ]

I have another question......

When I took out/off the vacuum disconnect I didn't notice how it was in there. Not that it would have mattered much because it was all busted up in there. When I go to put the new motor in, which shaft (intermediate or inner) do I put the shift collar on? I think I put it on the intermediate shaft, but I could be wrong. When I figure out which shaft to put it on, I just put the fork over the shift collar and bolt the assembly down, right? I looked in Chilton's for directions, and that sounds like all I have to do..........is that correct? TIA

[BFJ93YJ]

Thanks for all of the help!

I tried to put the hub back on this morning, and it went on fine. I then installed the vac disconnet, filld it with fluid and took it on a test drive. It drives fine, but I haven't put it in 4wd yet so I'm not sure if I fixed that:)

I checked the lower steering knuckle every mile or so of driving to see if there was any diff fluid that had leaked out and pooled on the kunckle.......after the first 4-5 miles of driving, there was no diff fluid that had leaked out. But after I got home and it sat for about 20 (while I was washing it) I noticed a small puddle of fluid. Do you think I ruined the seal? If I did, wouldn't have been leaking right away? Is it possible that I over filled the diff and it's just leaking out excess fluid? TIA

[zman]

As far as the shift fork assembly. Just line it up with the collar and put it together. When you start the engine the vacum will slide the collar to the correct position.

I have the same leak and have yet to fix it. I did put in a new seal but I still have the problem. I have a few ideas.

1. The axle is not centered in the axel tube. (my ball joint may not be seated properly)
2. The seal that I installed is stock for a 93 YJ without ABS. It may be possible that a different seal is required for ABS axels, but I don't think so.
3. I damaged the seal when I installed the axel.

zman